Resinous compositions and articles of manufacture comprising them



PatentedlApr. 17, 1945 aEsrNoUs coMrcsrrroNs AND v or MANUFAc'rUaE comarsmo THEM witty Lyne Alderson, Jr., Wilmington, nel.. .ig-'

signor to E. I. du

Pont de Nemours Complain? Wilmington, Del., a corporation of Delaware No Drawing. Application my Serial No.v495,352

18 Claims.' (Cl. 260-38) This invention relates to plasticized polyvinyl acetal compositions, and more particularly to` plasticized` polyvinyl butyral compositions.

The general utility of plasticized polyvinyl acetal compositions in cloth and wire 'coating ap-` plications has heretofore been limited on account of the relative, high cost oi the polymers, their inability to withstand; extensive pigmentation(-A with cheapkllersfand a degree o1 water sensitivity greater than i`s permissible in electrical insulating materials.

'I'his invention has as an object the preparation of new and useful compositions of matter. A further object is the production of inexpensive plasticized polyvinyl acetal compositions which yield valuable coated fabrics and electrically insulated products. A still further object is to provide improved articles-of manufacture comprising coated fabrics and insulated'electrical conductors. Other objects will appear hereinafter.

The aboveobjects are accomplishedby blend- I ing or mixing intimately a polyvinyl acetal resin ,containing less than 25% unsubstituted or free hydroxyl groups with cycloaliphatic hydrocarbons which-are obtained by decomposing acid sludges which are formed during the rcning of petroleum and which have an iodine number of from 40 to 60 and correspond to the general for mula (Cambi where n has a value of from 8 to 25. These cycloaliphatic hydrocarbons are known products of high boiling point obtainedby ldecomposing selected acid sludges, e. g. waste prod product obtained iromphydrolyzed. polymerized a plurality of carbon atoms. The aldehydes are vthose other j than formaldehyde, and include acetaldehyde, propionaldehyde. butyraldehyde,

The compositions of, tbislinvention can-be prepared from polyvinyliacetairesins 'having-188s v than free hydroxyl groups. .It is preferred to use polyvinyl acetals ,containingy between 10% and 12% ireehyciroilyflil4 because these resins are more y compatible with the above described Naf tolen and withl other.4 blending,l agents.' By polyvinyl acetal resinsivismeant the condensation vinyl esters, and aldehydes or ketones -which have Iurfuralde'hyde,'A benzaldehyde, crotonaldehyde, and` ketonesl suchas acetone, 'cyclohexanona cyclopentanone. etc. Afmethod for their'prepara.

ucts of the petroleum industry, with certain catalysts. Their preparation and properties are more fully described in an article by Rostler and Mehner in India Rubber World of August l.

1941, pages 47 to 50, and in an article by Bornstein and Rostler in Modern 1942, as well as in United States Patents 2,185,` 952, 2,185,951, and 2,217,919. These hydrocar- Plastics of April bons.' suitably processed to render them free from inorganic impurities, are availableV under the trade name oi Nafto1en" in several grades which have essentially the same chemical composition but which vary in molecular weight from 300 to 1000 and .in viscosity at 212 F. from 7 to 540 centipoises. Although all these grades are suitable for the present purpose, the best results are obtained with the product designatedas Naftolen Rf-100 which comprises a mixture of the various iifrades of hydrocarbons of Naftolen and which has a viscosity at 2121 F. of 21 centipoises. It is this product that is designated by the reference to unsaturated cycloaliphatic hydrocarbons in the examples given below.

613;: The polyvinylbutyr'als are preferred in .the

practice ot this' invention. The l polyvinyl for.-

mals, obtained fromformi?.l'clehyde,v` are inoperable for making the 'present compositions.

polyvinyl' aetai'resins will depend on vthe u1timate properties desired in the anished product andl will vary -from 1% jto 200% by weight-oi the #wel .resin F0? mesi fvurvases.- imm 2.50% sto 100% of the hydrocarbon plasticiaer is adequate.

But since it Acan be in sucnliarge. amountsas up to 200%, and is also quite cheap, it is possible and orten.' advantageous to onset the high cost of the -acetal resin by incorporatingz large amounts o! the plastlcizer with the resin.-

In the preferred compositions, t oiwtlgisf invention, the polyvinyl Piided sin? parts ,by means of rolls; ,heated-ftd A05-100 z-i'rom which the eompgsitionrisfwbtaf ed apilable sheets which sardina@ the .;u1.tiv mate. use :or yhiclitne preda@ is intended. The

u' piastieized resin. for=..example..can beexf truded in uit loro ci maestras be aelendered to cloth. Othet'mnthvds otmmmuedinstlvr. in

stance by lo! a ,'suitableiisolvent, ,can

,In orden obtain-"producir which lean. bie-'ren'- derea anni. msmn-.mgmermtpasa am method .-for preparing the' c are coml invention.

free from teck by stumble nest treatment there Y For instance, when-extruded over wire and baked is incorporated in the composition a thermo-I setting formaldehyde derivative in amount of from 1% to 40% based on the weight of the acetal resin although 1% to 20% is usually preferred. These 'thermosetting compounds include condensation products of formaldehyde with phenols, urea, urea derivatives. melamine and amides. Compositions having the most desirable properties are obtained with a monohydric alcohol-modified urea-formaldehyde resin obtained by the process described in United States Patent 2,191,957.

The invention is further illustrated by thefollowing examples in which the parte are by weight.

Example I approximately 12.5% tree hydroxyl groups). 15

parts of a butanol-moulded urea-formaldehyde resin, dissolved in `butanol and I parts of the previously described mixture of unsaturated' cycloaiiphatic Vhydrocarbons v(Naftolen R-100) are allowed to soak 4in about 100 parts of ethyl alcohol for several hours. -The colloided mass is then compounded for 20 minutes on rolls heated to '1080 C. in order to remove the lasttraces of solvent. The composition is now ready for' fur ther processing. For instance, it can be extruded over wire by means of conventional equipment well known to the art to give a smooth, attractive coating which when heated for two hom-s' at 120 C. becomes extremely tough and nonetacky at temperatures as high as 200 C. The heat treated insulation is, furthermore. pliable and not brittle at temperatures as low as -20' C., resistant to cold flow at-moderate temperatures, and insoluble in organic solvents. trical properties of insulations appliedv in this manner are but slightly affected by prolonged following values are obtained: dielectric constant 3.1, power factor (1000 cycles per second) 0.04, volume resistivity in tap water at 20 C. the insulation has a'dielectric constant of 3.8, a power factor at 1000 The :ood elec--` 1014 ohm-cm. After 48 hours is obtained by colloiding 100 parts of a polyvinyl for 45 'minutes at 130-135 C. it forms an insulation which is very tough, non-tackyat 200 C.. insoluble in organic solvents, and which can be bent sharply at 40 C. without cracking. Its excellent water resistance and electrical' properties are indicated by the following data obtained before (dry) 'and' after (wet) 48 hours immersion inl tap water at C. Dielectric constants: dry 4.3, wet- 4.9.- Power factor at 1000 cycles/second; dry 0.05, wet 0.07. Volume resistivity: -dry 10M ohm-cm., wet approxima 1013 ohm-cm.

- V Ezampze 1u A composition which can be used to coat wire acetal resin obtained by reacting ahydrolysed. polymerized vinyl ester' with acetaldehyde and whichhas A80% of its hydroxyl groups acetaiiaed. parts of a 60% solution of a butanol-moulded urea-formaldehyde resin in butanol,A 70 parts of piasticizer consistingof the previously described imsaturated cycloaliphatic hydrocarbon mixture.

and 50 parts of denatured ethyl alcohol in a Werner l: Piieiderer mixer heated to 40-50 C. by means of low. pressure steam. The colloided polymer is then removed from the mixer and compounded on rolls heated-to 70 C. until me from solvent. ,Y

, Example IV A composition Aeminently suited for coatina cloth is prepared from the following materials as described below: one hundred parts of a polyl vinyl butyral resin having a hydroxyl number of 159, parts of the previously described mixture of unsaturated cycloaliphatic hydrocarbons. 25 parts of a- 60% solution of a butanol-modified urea-formaldehyde resin in butanol. 5 parte di- .49 butyl ammoniumoleate, 100 parts ethyl alcoimmersion in water; For instance. when dry the cycles/second of 0.06, and volume resistivity of 101* ohm-cm.

If a mineral-oil such as Nuioi," which is an: essentially saturated aliphatichydrocarbon mixture, is substituted for the unsaturated cycloaliphatic hydrocarbons used in the abovefexample a crumbly material is obtained which cannot be sheeted on hot rolls except. at very high temperatures to sive hard-brittle sheets. Thus it is evident that conventional mineral oils'are not compatible with *the preferred resins used for preparing, the compositions Example 11 X' of this.

Example I. 4 parte polyvinyl butyral impartito!alittlev mixture of unsaturated aliparte of ethyl alcohol.

heatedrolls non. ,75 b yspreadins with a doctor knife.

hol, 'l5 parts crown clay, and 2 parts of colored pigment. These materials, with the exception of the clay and colored pigment, are mixed with a paddle and allowed to stand for two hours and then milled on a. warm rubber mill (rolls heated to 4060 C.) until homogeneous and free from solvent. The clay and colored pigment are then milled into the composition, which is then trans fened to a three roll calender mill having upper, center. and lower rolls heated at 70, 75. and 30 as a 0.006" lm upon a light weight cotton sheeting which has been anchor coated as is described below. coated fabric is dusted with a mixture of -25% talc and '15% cornstarch and is than euren by baking for two hours at c. 'me cured coated fabric is not affected by boiling w 1 ter. and when the sample is folded coated si against coated `side and heated at 200 C. the coated surfaces show no tendency to stick together. The coated fabric does not crack upon folding at temperatures above 40 C. and in the cold crack tst. in .which a sample is folded under a standard impact. ldoes not fail at temperatures above 20 C. A

The anchor coated fabric` used above is pre- Apared in the following manner: one hundred parts-of a polyvinyl butyral resin (hydroiql number 159), 100 parts of di-(secondary octyllphtbalate', 28 'parts of a. 60% solution of a butanoliiied urea-formaldehyde resin in butanol. 250 parts of denatured ethyl alcohol are stirred together untilsolution is complete'. solution is then applied to a light weight cotton sheeting A film weigh.

respectively. The composition is calenderedmented more satisfactorily.. For instance. the

uncured coated fabric is cut to pattern, assembled, and cemented with .an alcohol solution of. the

following materials: one hundred parts of a polyy vinyl -butyrl resin (hydroxyl number 159), .75 v parts di(sec.octyl) phthalate, 50 parts of the previously described unsaturated cycloaliphatic ily-' drocarbon plasticizer, 25 parts of a 60% solution of butanol-modified urea-formaldehyde resin in butanol, 75 .parts crown clay, and 2 parts color pigment. Following assembly and cementing, the coats arecured for one hour at 260 F. to render the coating and seams insoluble and'non-thermoplastic. -l

EzrampleV "A composition is prepared from the following materials bythe method described in Example 1111.' One hundred parts of a polyvinyl butyral resin of hydroxyl number 159, 30 parts of di(se c. octyllphthalate, 100 parts of the` previously de'- scribed vunsaturated cycloaliphatic hydrocarbon plasticizer, 28 parts of a 60%' solution of a butanol-modie'd urea-formaldehyde resin disi lsolved in butanol, parts dibutyl ammonium oleate', 3,00 parts crown clay, 2.8 partscolor pigment.. This composition is calendered with a three roll calender mill having upper, center, and

llower rolls heated.at.'10, 80, and 35 C., respectively, upon the anchor coated sheeting described in Example III. Thecoated fabric, after'fcuri'ng for 1.5 hours at 120 C., is very soft and pliable.' It is not softened by boiling water or by holding coated side against coated side at temperatures as high as.200 C. In spite of the-'large amount of clay filler employed, the coating is tough. abrasionfr esistant, and does not crack when foldedat temperatures above -20".C!. or atvtemperatures above C. inthe cold crack test. The coated i. fabric is .suitable for use in the manufacture of raincoats, Coats and other articles which have cemented 'seams are preferably fabricated from the uncured coated fabric and subsequently cured v by baking 'as is described in Example IV.

Tolmpar't certain additionalspeciflc properties to the'ilnished compositions and to adapt them to speciied uses it is often desirable to use the previously described unsaturated cycloaliphatic hydrocarbon plasticizer inl conjunction with other plasticizers. Thus, if a high order'of' low temperature` pliability and toughness are-deaired, vthefmixture of unsaturated cycloaliphatic ples can b e blended i 'with various amounts, depending on the degree hyrocarbons used in the exam of flexibility desired, of castor oil, acetylated oury tor oil. phthalic esters such as dicaprylphthalate, clioctyl phthalate. 4dibutyl fphthalate, dibutoxyethyl phthalate; or esters of higher aliphatic acids such as butyl sebacate. methyl acetyl ricinoleate, dibutyl vCellosolve .sebacatav di-(butylcarbitoliglutara'te; or Aesters 'of phosphoric acid such as trici-esyl phosphate. trioctyl phosphate, or triphenyl phosphate.

The compositions of this invention can be preparedby means of the standard type of mixing equipment availablev to the chemical industry. Although it is generally more expedient to soften` the. polyvinyl acetal resin with a' low boiling sol'- vent auch as acetone or a lower aliphatic alcohol prior to compounding, this is not necessary and ltiscntirely feasibletomixthevariousingredients directly by compounding atv elevated tem Peraturcs (80,'-150 CJ.

The compositions of this thermore c ontain from 1% up to as much as 300%, based on the weight of the polyvinyl acetal resin, of cheap fillers such as clay without adversely affecting their inherent toughness, pliability.. and good aging characteristics. Almost any type of pigment or filler can be used for this purpose; for instance, carbon black, bone black, clay, barytes, titanium dioxide, zinc oxide'calcium sulfate.. calcium hydroxide, magnesium carbonate, various dyes and colored pigments, etc.

This fact, together-With the feasibility of using I unusually large amounts of the previously described unsaturated cycloaliphatic hydrocarbon plasticizers makes possible the production of inexpensive but valuable polyvinyl acetal resin compositions containing buta relatively small amount of the resin.

In addition to being adaptable tocalendering, friction coating, extrusion and spreading techniques, the new compositions of polyvinyl acetal resins and cycloali'phatic'hydrocarbons described .25 herein can be applied from solution. This latter methodis particularly advantageous in the coating of wire, e. g. in magnet wire coating.

The ability, previously mentioned, of the present compositions to withstand an exceptionally 30 high degree'of pigmentation with cheap fillers o and the resultant decrease in cost thus effected renders them-very useful as fabric coatingfcompositions foruse in the manufacture of raincoats,

sport Jackets, .nospim sheeting, @nonterminal cells. water containers, luggage, footwear. and .protectivecoverings such as tarpaulins, tents, lsleeping bags', automobile ytops, awnings,v etc. Their excellent electrical propertiesand high degreeof water resistance, as well'as their good g agingfcharacter'istics, enhance theirutility as insulation for various types of electrical conductors such as communications wires, ordinary .household wiring, lamp cords, etc. 'They are also useful/in preparing protective jackets for all types of electric cables. In addition, these compositions can be used to. prepare molded articles of all kinds, abrasive compositions, adhesives, caps, closures.' collapsible containers, tubes, rods, tapes,

fibers, storage battery plate separators, wrapping foils, .shoe soles and heels, gaskets for preserving -'.1ars,'etc'.

As many .apparently widely dierent embodiments of this invention may be made without departing .from the spirit andsscope thereof, it is to be understood that I do-not limit myself to.

the specific embodiments thereof except as defined in the appended claims.

I clail'n:

" l. A composition of matter comprising :a1-'poly-` v00 vinyl acetal resin containing less than 25% 1free hydroxyl groups and in which the acetal' portion is derived'from a substance selected from the group consisting of aldehydes and ketones having at least two carbon atoms, with unsaturated re5 cycloaliphatic hydrocarbons obtained by decomposing with alkaline neutralizing agents acid sludges formed in the refining ofA petroleum, said hydrocarbons having an iodine number of from e 4.0 to 60. a'viscosity at 212 F. of 7 to 540 centipaises' and an approximate formula (Calma -w'here n represents an integer of from 8 to 25.

2. A' composition of matter comprising. poly- .vinyl` butyrai resin containing lessthan 25% free hydroxyl groups plasticized with unsaturated 7 0 cycloaliphatic hydrocarbons obtained by decomposing wil-.n alkaline neun-annua agente eem sludges formed in the refining of petroleum. said hydrocarbon having an iodine number of from 40 to 60. a viscosity at 212 F. of 7 to 540 centipoises, and an approximate formula (Cal-I4);

where n represents an integer of from 8'to 25.

3. A composition of matter Ycomprising a polyvinyl acetal resin containing less than 25% free hydroxyl groups and-in which the acetal portion is derived from a substance selected from the group consisting of aldehydes and ketones having atleast two carbon atoms, with unsaturatedA cycloaliphatic hydrocarbons obtained by decomposing with alkaline neutralizing agents acid sludges formed in the refining of petroleum, said hydrocarbons having an iodine number of from 40 to 60. a viscosity at 212 F. of approximately 21 centipoises and an approximate formula (03H4), where n represents an integer of from 8 to 25. A

v4. The composition set forth in claim 1 in which said unsaturated cycloaliphatic hydrocarbon is present in amount of 1% to 200% based on the weight of the resin.

5. The composition set forth in claim 3 in which said unsaturated cycloaliphatic hydrocarbon is present in amount of 1% to 200% based on the weight of the resin.

8. A composition of matter which comprises a polyvinyl acetal resin containing less than 25% free hydroxyl groups and in which the acetai portion is derived from an aldehyde having at least two carbon atoms, a plasticizer comprising unsaturated cycloaliphatic hydrocarbons obtained by decomposing with alkaline neutralizing agents acidsludges formed in the rening of petroleum, said hydrocarbons having an iodine number of from 40 to 60, a viscosity at 212 F.

of 7 to 540 centipoises and an approximate formula (Cal-14) where Vn represents an integer of 'fromB to 25, arlinert filler in an amount of 1% to 300% based. on the weight of the polyvinyl acetal resin, and'in an amount of from 1% to`l 20% of a condensation product of formaldehyde with a substance of the group consisting of phenoLVurea, and melamine.

7. A composition of matter which comprises polyvinyl butyral resin containingiess than 25%A free hydroxyl groups, a plasticizer comprising unsaturated cycloaliphatic hydrocarbons obtained by decomposing with alkaline neutralizing agents.

` 4 aanhef acid sludges formed inthe refining of petroleum, said hydrocarbons having an iodine number of from 40 to 60, a viscosity at 212 F. of v7 to 540 centipoises and an approximate formula (Calida where n represents an integer of from 8 to 25,

an inert filler in an amount of 1% to 300% based on the weight of the polyvinyl butyral resin, and

in an amount of from 1% to 20% of a .condensation product'of formaldehyde with a substance 10 of the group consisting of phenol. urea, and melamine. i

8. The composition set forth in claim 7 in which said hydrocarbon has a viscosity at 212 F. of 21 centipoiscs.`

l5' 9. The compos-meneer. forth in claim s ln which said condensation product of formaldehyde is a monohydric alcohol-modified urea-formaldehyde resin.

10. The composition set forth in claim 7 in 2o which said condensation product of formaldehyde "is a monohydric alcohol-modified urea-formaldehyde resin.

11. An' insulated electrical conductor in which the insulation comprises the composition set forth 12. an insulated electrical conductor ln which the insulation comprises the composition set forth in claim 2. Y

13. An insulated electrical conductor m wmen 3u the insulation comprises the composition set forth in claim 3. A.

. v14. An insulated electrical conductor in which the insulation comprises the composition set .forth inclalmfz. "35 15. An article of manufacture comprising a fieidble fabric having a coating which is resistant to cracking on folding and which comprises the composition set forth in claim 1.

.16'. An article of lmanufacture comprising a w flexible fabric having'a coating which is resistant to cracking on -folding and which comprises. the

flexible fabric having a coating winch is resistant. o to cracking on folding and which comprises the com-position set forth in claim 7.

. WIT'I'Y' LYSLE ALDERSON, JR. v 

